A bumper production line with online laser punching function

Abstract

The application discloses a bumper production line with an online laser punching function, and belongs to the technical field of bumper production, and has the technical features that a conveying device for conveying bumpers and a buffer area on the conveying device are connected with an online laser punching unit; the bumper production line with the online laser punching function does not need to be moved away from the production line and utilizes laser processing, and is used for radar punching production of bumpers.

Description

Technical Field

[0001] This invention relates to a bumper production line, and more specifically, to a bumper production line with an online laser drilling function. Background Technology

[0002] In the current bumper casting production process, the cast products are conveyed through processes such as spraying, drying, and inspection. Then, the products are manually removed from the production line and transferred to the drilling equipment, where they are mechanically drilled using milling cutters and reamers. After drilling, they are then transported to the assembly process for assembly.

[0003] However, the above production method has the following technical problems: On the one hand, this production process requires one or two operators specifically responsible for moving, transferring, and loading / unloading workpieces off the assembly line, resulting in high labor costs. Furthermore, the low efficiency of workpiece transfer during multiple manual handling processes makes it difficult to match the high-speed, continuous production rhythm of the assembly line, thus hindering the overall production capacity increase. Simultaneously, the bumper's positioning reference deviates after painting, drying, and multiple handling processes, making it difficult to guarantee the positioning accuracy of the workpiece on the drilling equipment. This affects the accuracy of hole machining and easily leads to defective products.

[0004] On the other hand, the cutting edges of milling cutters and reamers gradually wear down during continuous cutting, resulting in a decrease in sharpness. Frequent machine stops are required to replace the tools, which not only leads to high tool consumable costs, but also further disrupts production continuity and exacerbates efficiency losses.

[0005] To address the aforementioned issues, some improvements have been proposed in existing technologies. For example, patent CN 223394548 U discloses a laser drilling system for automotive bumpers. This system uses laser processing to replace traditional milling cutters and reamers for mechanical cutting. An independent processing space is formed inside the bumper component, and a robot, laser, and bumper positioning components are installed within this space. The robot drives the laser to drill holes in the bumper. While this solution solves the tool wear problem through laser processing, the laser drilling system it provides is a processing station independent of the production line. Products still need to be moved from the production line and transferred to this independent processing space for processing, failing to solve the problems of production line cycle time limitations and positioning reference deviations caused by manual handling.

[0006] Therefore, how to provide a bumper drilling solution that can reduce manual intervention, lower labor and tooling costs, and improve production line continuity and machining accuracy is a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0007] The purpose of this invention is to address the shortcomings of the prior art by providing a bumper production line with online laser drilling function that does not require removal from the production line and utilizes laser processing.

[0008] The technical solution of this invention is implemented as follows: A bumper production line with online laser drilling function includes a conveying device for conveying bumpers and a buffer area on the conveying device, wherein the buffer area is connected to an online laser drilling unit.

[0009] In the aforementioned bumper production line with online laser drilling function, the output end of the laser drilling unit is sequentially connected to a spraying station, a drying station, an inspection station, and an assembly station.

[0010] In the aforementioned bumper production line with online laser drilling function, the online laser drilling unit includes a flexible positioning component installed on the production line. The flexible positioning component is located below the conveying device, and a laser drilling component is provided on the side of the flexible positioning component.

[0011] When the bumper is conveyed to the top of the flexible positioning component by the conveying device, the flexible positioning component fixes the bumper and drills holes by the laser drilling component.

[0012] In the aforementioned bumper production line with online laser drilling function, the flexible positioning component includes a frame, on which at least four multi-axis positioning robotic arms are provided. The multi-axis positioning robotic arms are arranged symmetrically in pairs, and each multi-axis positioning robotic arm has a pneumatic gripper at its free end for gripping the bumper. The frame is provided with at least one waste collection hopper that matches the drilling position.

[0013] In the aforementioned bumper production line with online laser drilling function, two-dimensional horizontal moving modules are symmetrically arranged on the frames on both sides along the forward direction of the conveying device. The two-dimensional horizontal moving modules are located between two multi-axis positioning robotic arms on the same side. Each two-dimensional horizontal moving module is provided with a mounting bracket, and the upper end of the mounting bracket is provided with a positioning suction cup for cooperating with the bumper.

[0014] In the aforementioned bumper production line with online laser drilling function, a horizontal moving platform is provided on the frame, and the multi-axis positioning robotic arm and waste collection hopper are both set on the horizontal moving platform.

[0015] The side of the frame closest to the material inlet is the loading position, and the other side is the punching position. Conveyor belts are installed on the front and rear sides of the frame as conveying devices for feeding and discharging. The end of the conveyor belt on the feeding side is located at the loading position, and the front end of the conveyor belt on the discharging side is located at the punching position.

[0016] Initially, the horizontal moving platform is located at the loading end; after the multi-axis positioning robotic arm picks up the bumper, the horizontal moving platform moves to the drilling position.

[0017] In the aforementioned bumper production line with online laser drilling function, a discharge hopper is provided on the frame at the drilling position, and a discharge conveyor belt is provided on the lower side of the discharge hopper; a discharge pipe is connected to the lower end of the side wall of the waste collection hopper, and when the horizontal moving platform moves to the drilling position, the discharge port of the discharge pipe is opposite to the discharge hopper.

[0018] In the aforementioned bumper production line with online laser drilling function, the laser drilling assembly includes a multi-axis drilling robot arm disposed on the side of the flexible positioning assembly, a fiber laser is disposed at the free end of the multi-axis drilling robot arm, and an image positioning module is disposed on the multi-axis drilling robot arm on the side of the fiber laser.

[0019] In the aforementioned bumper production line with online laser drilling function, the image positioning module includes a mounting base set on a multi-axis drilling robot arm. The mounting base is equipped with an image acquisition device, the axis of which is parallel to the axis of the fiber laser. A supplementary light is provided below the image acquisition device to illuminate the bumper.

[0020] In the aforementioned bumper production line with online laser drilling function, the fill light is a ring fill light, and the image acquisition device is coaxially arranged with the ring fill light.

[0021] Compared with the prior art, the beneficial effects of the present invention are as follows: With the above structure, an online laser drilling unit is connected to the buffer area. During the bumper's conveyor buffer period, the bumper is drilled by the online laser drilling unit. The workpiece does not need to be transferred off the line; it is processed in situ on the production line, eliminating the need for transfer procedures and associated labor. By utilizing the buffer waiting time, the processing efficiency can be increased by about one-third compared to traditional milling, effectively improving bumper production capacity. Furthermore, the use of non-contact laser drilling eliminates tool wear, effectively reducing overall production costs. Attached Figure Description

[0022] The present invention will be further described in detail below with reference to the embodiments shown in the accompanying drawings, but this does not constitute any limitation on the present invention.

[0023] Figure 1 This is a flow chart of the production line of the present invention; Figure 2 This is a schematic diagram of the structure of the present invention; Figure 3 This is a schematic diagram of the online laser drilling unit of the present invention; Figure 4 This is a schematic diagram of the flexible positioning component of the present invention; Figure 5 This is a cross-sectional structural diagram of the flexible positioning component of the present invention; Figure 6 This is a schematic diagram of the structure of the two-dimensional horizontal movement module of the present invention; Figure 7 This is a schematic diagram of the structure of the laser drilling component of the present invention.

[0024] In the diagram: 1. Buffer area; 2. Conveying device; 3. Online laser drilling unit; 4. Spraying station; 5. Drying station; 6. Inspection station; 7. Assembly station; 8. Flexible positioning component; 8a. Frame; 8b. Multi-axis positioning robotic arm; 8c. Pneumatic gripper; 8d. Waste collection hopper; 8e. Two-dimensional horizontal moving module; 8f. Mounting support; 8g. Positioning suction cup; 9. Laser drilling component; 9a. Multi-axis drilling robotic arm; 9b. Fiber laser; 10. Horizontal moving platform; 11. Discharge hopper; 12. Discharge conveyor belt; 13. Discharge pipe; 14. Image positioning module; 14a. Mounting base; 14b. Image acquisition equipment; 14c. Supplemental lighting. Detailed Implementation

[0025] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments. Unless otherwise specified, the materials and equipment used in this embodiment are commercially available. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application.

[0026] In the description of this application, it should be understood that the terms "upper," "lower," "front," "rear," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this application. In the description of this application, "a plurality of" means two or more, unless otherwise precisely specified.

[0027] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "connected," "linked," and "connected" should be interpreted broadly. For example, they can refer to a fixed connection, a connection through an intermediary, or a connection within two elements or an interaction between two elements. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0028] The terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such process, method, product, or apparatus.

[0029] See Figure 1-7 As shown, a bumper production line with online laser drilling function according to the present invention includes a conveying device 2 for conveying bumpers and a buffer area 1 on the conveying device 2, wherein the buffer area 1 is connected to an online laser drilling unit 3.

[0030] The general process of a bumper production line is as follows: injection molding → buffering and handling → spraying and drying → defect detection and defective product sorting → parts assembly.

[0031] When bumpers are transported between different stages of the production line, they are temporarily stored in a buffer area before proceeding to the next stage. For example, after injection molding, the bumper is transported to the buffer area by a conveyor (such as an RGV rail-guided vehicle) to await the painting process. This period of temporary storage in the buffer area is called the transport buffer period.

[0032] An online laser drilling unit is connected to the buffer area. During the bumper's buffer period, the bumper is drilled by the online laser drilling unit, eliminating the need for off-line transfer. The workpiece is processed in situ on the production line, saving on transfer procedures and associated labor. Utilizing the buffer waiting time, processing efficiency is increased by about one-third compared to traditional milling, effectively improving bumper production capacity. Furthermore, the use of non-contact laser drilling eliminates tool wear, effectively reducing overall production costs.

[0033] In this embodiment, preferably, the output end of the laser drilling unit 3 is sequentially connected to a spraying station 4, a drying station 5, an inspection station 6, and an assembly station 7.

[0034] By placing the online laser drilling unit between the buffer area and the spraying station, the bumper is drilled first and then sprayed. This allows for painting of the inner surface of the through holes, which reduces the possibility of rust on the inner surface of the through holes compared to the existing method of spraying before drilling.

[0035] In this embodiment, the online laser drilling unit 3 includes a flexible positioning component 8 disposed on the production line. The flexible positioning component 8 is located below the conveying device 2, and a laser drilling component 9 is disposed on the side of the flexible positioning component 8.

[0036] When the bumper is conveyed to the top of the flexible positioning component 8 via the conveying device 2, the flexible positioning component 8 fixes the bumper and drills holes via the laser drilling component 9.

[0037] In current production, punched bumpers require specialized tooling for positioning. Different bumper sizes and shapes necessitate different tooling, making it incompatible with multi-model production lines. This solution utilizes flexible positioning, offering a more adaptable solution that can be quickly switched to suit multiple vehicle models.

[0038] In this embodiment, the laser drilling assembly uses a fiber laser cutter. Fiber laser machines only require cleaning of the fiber during maintenance; there is no need for periodic gas and lens replacements, making operation convenient and maintenance costs low. Furthermore, fiber lasers have higher electro-optical efficiency than carbon dioxide lasers, resulting in lower power consumption during extended operation.

[0039] Carbon dioxide lasers, with a wavelength of 1060nm, are suitable for cutting non-metallic materials, but their longer wavelength, relatively large spot size, and wider heat diffusion range can easily deform thin-walled or precision parts. Fiber lasers, using rare-earth-doped optical fibers as their core, have wavelengths of 1060nm or 1080nm. While more suitable for metallic materials, they can also be used for cutting resin materials. In applying fiber lasers to bumper cutting, multiple experiments were conducted to select different wavelengths. After numerous experiments, it was found that when the wavelength was between 1073.0-1075.5nm, the roundness of the cut holes met the production quality requirements.

[0040] Some experimental data are shown in the table below: Preferably, the flexible positioning component 8 includes a frame 8a, on which at least four multi-axis positioning robotic arms 8b are mounted. The multi-axis positioning robotic arms 8b are symmetrically arranged in pairs, and each multi-axis positioning robotic arm 8b has a pneumatic gripper 8c at its free end for gripping the bumper. The frame 8a also has at least one waste collection hopper 8d that corresponds to the drilling position. By controlling the operation of the multi-axis robot, different positioning positions can be changed to achieve flexible positioning, improve positioning flexibility, and quickly adapt to multiple vehicle models. The multi-axis robot and its position control software are existing mature equipment that can be skillfully operated by those skilled in the art, and will not be described in detail here.

[0041] Waste generated from drilling is collected in a waste collection hopper, which facilitates cleaning and prevents waste residue from falling into the equipment and causing interference.

[0042] In this embodiment, two-dimensional horizontal moving modules 8e are symmetrically arranged on the frame 8a on both sides of the forward direction of the conveying device 2. The two-dimensional horizontal moving modules 8e are located between two multi-axis positioning robotic arms 8b on the same side. Each two-dimensional horizontal moving module 8e is provided with a mounting bracket 8f, and the upper end of the mounting bracket 8f is provided with a positioning suction cup 8g for cooperating with the bumper.

[0043] When the multi-axis positioning robotic arm picks up the bumper, the positioning suction cups on both sides position and support the bumper, preventing the bumper from bending inward and sliding to the sides, thus ensuring the accuracy of the drilling position.

[0044] Meanwhile, the position of the positioning suction cup can be adjusted through the two-dimensional horizontal moving module to adapt to different bumper specifications and quickly switch to adapt to multiple car models.

[0045] More preferably, a horizontal moving platform 10 is provided on the frame 8a, and the multi-axis positioning robotic arm 8b and the waste collection hopper 8d are both mounted on the horizontal moving platform 10. The horizontal moving platform includes a track, a sliding platform, and a fixed push rod mounted on the frame. Other conventional driving methods such as cylinders can also be used. This is common knowledge to those skilled in the art and is not a technical point to be protected by this invention, so it will not be described in detail here.

[0046] The frame 8a has a loading position on the side closest to the material inlet and a punching position on the other side. Conveyor belts are set on the front and rear sides of the frame 8a as conveying devices 2 for feeding and discharging. The end of the conveyor belt on the feeding side is located at the loading position, and the front end of the conveyor belt on the discharging side is located at the punching position. In the initial state, the horizontal moving platform 10 is located at the loading end. After the multi-axis positioning robotic arm 8b picks up the bumper, the horizontal moving platform 10 moves to the punching position.

[0047] While the bumper is being punched, the feed conveyor belt can continue to transport it to the loading position to await punching. When the bumper is waiting to be picked up at the loading position, the feed conveyor belt needs to stop running. At this time, the discharge conveyor belt can continue to transport the punched bumper to the next station, ensuring production efficiency.

[0048] Furthermore, when processing bumpers of different specifications, the distances on both sides of the bumper after reaching the end are different. The position of the multi-axis positioning robotic arm can be adjusted by the horizontal moving platform to further extend the operating range of the robotic arm and improve its flexibility.

[0049] Preferably, a discharge hopper 11 is provided on the frame 8a at the punching position, and a discharge conveyor belt 12 is provided on the lower side of the discharge hopper 11; a discharge pipe 13 is connected to the lower end of the side wall of the waste collection hopper 8d, and when the horizontal moving platform 10 moves to the punching position, the discharge port of the discharge pipe 13 is opposite to the discharge hopper 11.

[0050] Waste collected in the waste collection hopper is then discharged onto the discharge conveyor belt after being concentrated in the discharge hopper. A collection box can be installed at the outer end of the discharge conveyor belt for easy collection and cleaning.

[0051] In this embodiment, the laser drilling assembly 9 includes a multi-axis drilling robotic arm 9a disposed on the side of the flexible positioning assembly 8. A fiber laser 9b is disposed at the free end of the multi-axis drilling robotic arm 9a, and an image positioning module 14 is disposed on the multi-axis drilling robotic arm 9a on one side of the fiber laser 9b. The multi-axis drilling robotic arm can change various angles, and with the real-time positioning of the image positioning module, it can flexibly find the drilling position, ensure drilling accuracy, effectively ensure drilling consistency, and improve product quality.

[0052] In this embodiment, preferably, the image positioning module 14 includes a mounting base 14a disposed on the multi-axis drilling robotic arm 9a. An image acquisition device 14b is mounted on the mounting base 14a, and the axis of the image acquisition device 14b is parallel to the axis of the fiber laser 9b. A supplementary light 14c is disposed below the image acquisition device 14b to illuminate the bumper. In this embodiment, the image acquisition device used is an industrial camera. The specific model selection and installation method of the industrial camera are common knowledge to those skilled in the art and will not be elaborated upon here.

[0053] The image acquisition device is connected to an operating platform such as a computer or mobile phone. After the image acquisition device captures images in real time, it performs real-time analysis and positioning through image comparison software on the operating platform. Image comparison software technology is a common and mature technology on the market, which can be directly used by those skilled in the art after purchasing it and modifying and debugging the corresponding parameters. It will not be described in detail here.

[0054] More preferably, the fill light 14c is a ring fill light, and the image acquisition device 14b is coaxially arranged with the ring fill light. The ring fill light can provide all-around illumination for the image acquisition device, ensuring the clarity of the image and improving the accuracy of image comparison.

[0055] Each component is equipped with a corresponding sensor, and depending on the specific requirements and complexity, existing control boxes, microcontrollers, or PLCs are used to control the drive components of each component. Throughout the operation, the timing of coordination between different processes, achieved through various sensors, depends on the specific circumstances. The goal is to ensure that each unit can smoothly execute its corresponding instructions. The aforementioned sensors and control terminals are common knowledge to those skilled in the art and are not the technical points to be protected in this invention; therefore, they will not be elaborated upon here.

[0056] During operation, the bumpers cast in the buffer area are output through the conveying device. When the bumper reaches the loading position of the frame, the multi-axis positioning robotic arm moves according to the preset data to make the pneumatic gripper cooperate with the edge of the bumper to clamp and lift the bumper. At the same time, the two-dimensional horizontal moving modules on both sides drive the positioning suction cups to cooperate with the inner walls on both sides of the bumper. Then the horizontal moving platform moves to transfer the bumper to the drilling position.

[0057] The multi-axis drilling robot arm moves to the position above the bumper to drill holes according to preset parameters, and adjusts its position in real time through images captured by the image acquisition device. After finding the drilling position, it uses a fiber laser to emit a laser to cut and drill holes in the bumper.

[0058] The above-described embodiments are preferred embodiments of the present invention and are only used to facilitate the illustration of the present invention. They are not intended to limit the present invention in any way and should not be construed as limiting the scope of protection of the present invention. Any equivalent embodiments made by those skilled in the art without departing from the technical features disclosed in the present invention, such as changes in the size, dimensions, structure, shape and proportion of various elements, installation arrangement, material use, color, orientation, etc., and without departing from the technical features of the present invention, shall still fall within the scope of the technical features of the present invention.

Claims

1. A bumper production line with online laser drilling function, comprising a conveying device (2) for conveying bumpers and a buffer area (1) on the conveying device (2), characterized in that, The buffer area (1) is connected to an online laser drilling unit (3).

2. The bumper production line with online laser drilling function according to claim 1, characterized in that, The output end of the laser drilling unit (3) is sequentially connected to the spraying station (4), drying station (5), inspection station (6) and assembly station (7).

3. A bumper production line with online laser drilling function according to claim 1 or 2, characterized in that, The online laser drilling unit (3) includes: A flexible positioning component (8) is installed on the production line. The flexible positioning component (8) is located below the conveying device (2). A laser drilling component (9) is provided on the side of the flexible positioning component (8). When the bumper is conveyed to the top of the flexible positioning component (8) by the conveying device (2), the flexible positioning component (8) fixes the bumper and drills holes by the laser drilling component (9).

4. A bumper production line with online laser drilling function according to claim 3, characterized in that, The flexible positioning component (8) includes: The frame (8a) is provided with at least four multi-axis positioning robotic arms (8b), which are symmetrically arranged in pairs. Each multi-axis positioning robotic arm (8b) has a pneumatic gripper (8c) for gripping the bumper at its free end. The frame (8a) is provided with at least one waste collection hopper (8d) that matches the drilling position.

5. A bumper production line with online laser drilling function according to claim 4, characterized in that, Two-dimensional horizontal moving modules (8e) are symmetrically arranged on the frame (8a) on both sides of the forward direction of the conveying device (2). The two-dimensional horizontal moving modules (8e) are located between two multi-axis positioning robotic arms (8b) on the same side. Each two-dimensional horizontal moving module (8e) is provided with a mounting bracket (8f). The upper end of the mounting bracket (8f) is provided with a positioning suction cup (8g) for cooperating with the bumper.

6. A bumper production line with online laser drilling function according to claim 4, characterized in that, The frame (8a) is provided with a horizontal moving platform (10), and the multi-axis positioning robotic arm (8b) and the waste collection hopper (8d) are both set on the horizontal moving platform (10); The frame (8a) has a feeding position on the side closest to the material inlet and a punching position on the other side; conveyor belts are set on the front and rear sides of the frame (8a) as conveying devices (2) for feeding and discharging, with the end of the conveyor belt on the feeding side located at the feeding position and the front end of the conveyor belt on the discharging side located at the punching position. In the initial state, the horizontal moving platform (10) is located at the loading end; after the multi-axis positioning robot arm (8b) picks up the bumper, the horizontal moving platform (10) moves to the punching position.

7. A bumper production line with online laser drilling function according to claim 6, characterized in that, A discharge hopper (11) is provided on the frame (8a) at the punching position, and a discharge conveyor belt (12) is provided on the lower side of the discharge hopper (11); a discharge pipe (13) is connected to the lower end of the side wall of the waste collection hopper (8d). When the horizontal moving platform (10) moves to the punching position, the discharge port of the discharge pipe (13) is opposite to the discharge hopper (11).

8. A bumper production line with online laser drilling function according to claim 1 or 2, characterized in that, The laser drilling assembly (9) includes: A multi-axis drilling robot arm (9a) is set on the side of the flexible positioning component (8). A fiber laser (9b) is provided at the free end of the multi-axis drilling robot arm (9a). An image positioning module (14) is provided on the multi-axis drilling robot arm (9a) on the side of the fiber laser (9b).

9. A bumper production line with online laser drilling function according to claim 8, characterized in that, The image positioning module (14) includes: A mounting base (14a) is set on a multi-axis drilling robot arm (9a). An image acquisition device (14b) is provided on the mounting base (14a). The axis of the image acquisition device (14b) is parallel to the axis of the fiber laser (9b). A supplementary light (14c) is provided below the image acquisition device (14b) to illuminate the bumper.

10. A bumper production line with online laser drilling function according to claim 9, characterized in that, The fill light (14c) is a ring fill light, and the image acquisition device (14b) is coaxially arranged with the ring fill light.

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